CAMSHAFT INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repair" after replacing the camshaft, No. 2 camshaft, camshaft timing gear assembly or camshaft timing exhaust gear assembly.

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PROCEDURE


  1. INSTALL NO. 2 CAMSHAFT BEARING

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  2. INSTALL NO. 1 CAMSHAFT BEARING

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  3. INSTALL OIL CONTROL VALVE FILTER

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  4. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. Secure the No. 2 camshaft in a vise by clamping the hexagonal part between aluminum plates.

      Note

      Do not damage the No. 2 camshaft by tightening the vise excessively.

    2. A0028SAC26
      *a Knock Pin Hole
      *b Knock Pin

      Align and fit the knock pin of the No. 2 camshaft with the knock pin hole of the camshaft timing exhaust gear assembly.

    3. A002BAAC72
      *1 Camshaft Timing Exhaust Gear Assembly
      *2 Camshaft Flange
      *a Incorrect
      *b Correct
      *c Gap
      *d No Gap

      Check that there is no gap between the camshaft timing exhaust gear assembly and camshaft flange.

    4. A0028D5

      Secure the camshaft timing exhaust gear assembly with the bolt.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Note

      Do not disassemble the camshaft timing exhaust gear assembly.

      Tech Tips

      Perform "Inspection After Repair" after replacing the camshaft timing exhaust gear assembly.

      Click here

  5. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A0028NYC02
      *a Timing Notch (Groove)

      Turn the crankshaft pulley until its timing notch (groove) and the timing mark "0" of the timing chain cover sub-assembly are aligned.

  6. INSTALL NO.2 CAMSHAFT


    1. A002BKVC35
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap

      Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.

    2. Clean the camshaft journals.

    3. Apply a light coat of engine oil to the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.

    4. A0029JJC03
      *a Paint Mark
      *b Timing Mark

      Hold up the chain sub-assembly, align the timing mark and paint mark, and install the No. 2 camshaft.

      Tech Tips


      • "A" is not a timing mark.

      • Perform "Inspection After Repair" after replacing the No. 2 camshaft.

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  7. INSTALL CAMSHAFT


    1. A002BKVC36
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap

      Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.

    2. Clean the camshaft journals.

    3. Apply a light coat of engine oil to the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.

    4. A0028LGC08
      *a Knock Pin
      *b Approximately 17°

      Install the camshaft to the camshaft housing sub-assembly as shown in the illustration.

      Tech Tips

      Perform "Inspection After Repair" after replacing the camshaft.

      Click here

  8. INSTALL CAMSHAFT BEARING CAP


    1. A0029RP

      Confirm the marks and numbers on the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and 3 No. 3 camshaft bearing caps and place them in their proper positions and directions.

    2. A0027H3N04

      Uniformly tighten the 10 bolts in several steps in the order shown in the illustration.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }
    3. A0027NMN04

      Uniformly tighten the 11 bolts in several steps in the order shown in the illustration.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

    4. Check the torque of each bolt again.

  9. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. A00278JC25
      *a Advanced Position
      *b Retarded Position
      *c Alignment Mark
      *d Knock Pin Hole

      Check the camshaft timing gear assembly position.

      Note


      • If the camshaft timing gear assembly is set to the advanced position, do not let the camshaft timing gear assembly rotate clockwise during installation.

      • If the camshaft timing gear assembly has rotated to the most retarded position, make sure to release the lock pin and set the camshaft timing gear assembly to the most advanced position before tightening the bolt of the camshaft timing gear assembly.

    2. A002APFC09
      *a Narrow
      *b Wide

      Install the camshaft timing gear assembly as shown in the illustration.

    3. A002876C09
      *a Narrow
      *b Wide

      Turn the camshaft timing gear assembly approximately 180° counterclockwise.

    4. A002C81C12
      *a Paint Mark
      *b Timing Mark

      Align the paint mark with the timing mark and install the chain sub-assembly to the camshaft timing gear assembly.

      Tech Tips

      "A" is not a timing mark.

    5. A0027FQC54
      *a Knock Pin
      *b Knock Pin Hole

      Align and fit the knock pin of the camshaft with the knock pin hole of the camshaft timing gear assembly.

    6. A002BAAC73
      *1 Camshaft Timing Gear Assembly
      *2 Camshaft Flange
      *a Incorrect
      *b Correct
      *c Gap
      *d No Gap

      Check that there is no gap between the camshaft timing gear assembly and camshaft flange.

    7. Secure the camshaft in place by hand, and then install the bolt of the camshaft timing gear assembly by hand.

      Note

      Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

    8. If the lock pin has not been released, release it.


      1. A002BTCC08
        *a Make a Hole
        *b Adhesive Tape Sealing Area

        After cleaning the intake side VVT oil hole on the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.

        Note

        Be sure to seal the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

      2. Make a hole in the adhesive tape covering the oil hole as shown in the illustration. (Procedure A)

      3. A002C2E

        Apply approximately 200 kPa (2.0 kgf/ cm2, 29 psi) of air pressure to the hole made in procedure A to release the lock pin.

        Note


        • If air leaks out, reattach the adhesive tape.

        • Cover the oil hole with a piece of cloth when applying air pressure to prevent oil from spraying.

      4. Forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

        Tech Tips


        • Depending on the air pressure applied, the camshaft timing gear assembly may turn in the advance direction without assistance by hand.

        • If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.

      5. Remove the adhesive tape from the No. 1 camshaft bearing cap.

    9. A002AFZC01
      *a Hold
      *b Turn

      Using a wrench to hold the hexagonal portion of the camshaft, install the bolt.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Note

      Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.

    10. A0029GUC03
      *a Paint Mark
      *b Timing Mark

      Check that both timing marks on the camshaft timing gear assembly and camshaft timing exhaust gear assembly are facing upward as shown in the illustration.

      Tech Tips


      • "A" is not a timing mark.

      • Perform "Inspection After Repair" after replacing the camshaft timing gear assembly.

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  10. ADD ENGINE OIL

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  11. INSTALL TIMING CHAIN GUIDE

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  12. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A00297TN02

      Turn the crankshaft pulley approximately 10° clockwise.

    2. Install a new gasket and the No. 1 chain tensioner assembly with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note

      Make sure not to drop the gasket inside the timing chain cover sub-assembly.

    3. Remove the pin from the stopper plate.

  13. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Turn the crankshaft pulley until its timing notch (groove) and the timing mark "0" of the timing chain cover sub-assembly are aligned.

      A0027GUC02
      *a Timing Mark *b Timing Notch
      *c Approximately 7° *d Approximately 32°

    2. Check that both timing marks on the camshaft timing gear assembly and camshaft timing exhaust gear assembly are facing upward as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration.

      Tech Tips

      "A" is not a timing mark.

  14. INSTALL TIMING CHAIN COVER PLATE


    1. Install a new gasket and the timing chain cover plate with the 4 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  15. INSTALL TIMING CHAIN COVER TIGHT PLUG

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  16. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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  17. INSTALL IGNITION COIL ASSEMBLY

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  18. CONNECT ENGINE WIRE


    1. Install the engine wire to the engine assembly with the 3 bolts and 4 nuts.

      A002BTTN01
      Torque:
      Nut (A)
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
      Nut (B)
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }
      Bolt
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    2. Connect the 12 connectors and 5 clamps.

    3. Engage the 2 claws to connect the inlet heater water hose and outlet heater water hose A.

  19. INSTALL ENGINE MOVING CONTROL ROD

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  20. INSTALL NO. 2 ENGINE MOUNTING STAY RH

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  21. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

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  22. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

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  23. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

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  24. INSTALL INLET AIR CLEANER ASSEMBLY

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  25. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

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  26. INSTALL COOL AIR INTAKE DUCT SEAL

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  27. INSTALL RADIATOR SIDE SEAL RH

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  28. INSTALL RADIATOR SIDE DEFLECTOR SEAL LH

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  29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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  30. INSPECT FOR OIL LEAK

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  31. INSTALL FRONT FENDER APRON SEAL RH

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  32. INSTALL FRONT FENDER LINER RH

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  33. INSTALL NO. 1 ENGINE UNDER COVER

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  34. INSTALL FRONT WHEEL RH

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }